Polymer composite foams

1. A method of forming a polymeric foam with a uniform cell size distribution, the method comprising:

forming a concentrate composition comprising at least one carrier and dispersed therein from about 5% to about 70% by weight of at least one surface unmodified sepiolite clay;

incorporating the concentrate composition into a polymer matrix, wherein the polymer matrix is selected from the group consisting of polystyrene, polyethylene, ethylene vinyl acetate (EVA), maleic anhydride grafted polymers, polyethylene terephthalate, poly(methyl methacrylate) (PMMA), polyamide, polycarbonate, styrene butadiene copolymers, acrylonitrile butadiene styrene, styrene acrylonitrile, styrene block copolymers, ethylene methyl acrylate copolymers, polyacrylonitriles, polyvinyl chloride, polyvinyl alcohol, melamine formaldehyde, urea formaldehyde, polymethyleneurea, natural rubber, synthetic rubber, elastomers, biodegradable polymers, amino resins, alkyd resins, phenolic resins, epoxy resins, isocyanate resins, isocyanurate resins, polysiloxane resins, and mixtures thereof;

introducing at least one blowing agent into the polymer matrix and incorporated concentrate composition; and

processing the polymer matrix with the concentrate composition and at least one blowing agent, to thereby produce the polymeric foam having a uniform cell size distribution,

wherein the concentrate composition provides from about 0.10% to about 2.0% of the at least one surface unmodified sepiolite clay by weight of the polymer matrix with the concentrate composition, and

wherein the at least one carrier comprises a thermoset polymer.

2. The method according to claim 1 , wherein the concentrate composition provides from about 0.01% to about 5.0% of the at least one surface unmodified sepiolite clay by weight of the polymer matrix with the concentrate composition.

3. The method according to claim 1 , wherein the at least one surface unmodified sepiolite clay is heat treated.

4. The method according to claim 1 , wherein the at least one blowing agent is selected from the group consisting of organic blowing agents, inorganic blowing agents, chemical blowing agents, and combinations thereof.

5. The method according to claim 4 , wherein the at least one blowing agent consists of carbon dioxide.

6. The method according to claim 5 , wherein the carbon dioxide comprises supercritical carbon dioxide.

7. The method according to claim 1 , wherein the at least one carrier comprises a thermoplastic polymer.

8. The method according to claim 7 , wherein the thermoplastic polymer is selected from the group consisting of polystyrene, polyethylene, polypropylene, ethylene vinyl acetate (EVA), maleic anhydride grafted polymers, polyethylene terephthalate, poly(methyl methacrylate) (PMMA), polyamide, polyesters, polycarbonate, styrene butadiene copolymers, acrylonitrile butadiene styrene, styrene acrylonitrile, styrene block copolymers, ethylene methyl acrylate copolymers, polyacrylonitriles, polyurethane, polyvinyl chloride, polyvinyl alcohol, melamine formaldehyde, urea formaldehyde, polymethyleneurea, natural rubber, synthetic rubber, elastomers, biodegradable polymers, and mixtures thereof.

9. The method according to claim 1 , wherein the thermoset polymer is selected from the group consisting of unsaturated polyesters, polyurethanes, amino resins, alkyd resins, phenolic resins, epoxy resins, isocyanate resins, isocyanurate resins, polysiloxane resins, and mixtures thereof.

10. The method according to claim 1 , wherein the concentrate composition further comprises at least one additive agent also dispersed in the at least one carrier and is selected from the group consisting of flame retardants, secondary nucleating agents, dyes, pigments, lubricants, antistatic agents, biocides, aging modifiers, heat stabilizers, antioxidants, ultraviolet stabilizers, coupling agents, fillers, acid scavengers, preservatives, plasticizers, impact modifiers, chain extenders, graphite, graphene, hydrophilic agents, and combinations thereof.

11. The method according to claim 10 , wherein the at least one additive agent includes a secondary nucleating agent selected from the group consisting of talc, wollastonite, zeolite, diatomaceous earth, a molecular sieve material, or combinations thereof.

12. The method according to claim 10 , wherein the at least one additive agent includes a flame retardant additive selected from the group consisting of halogenated compounds, halogen-free compounds, phosphorous compounds, nitrogen-based compounds, and combinations thereof.

13. The method according to claim 12 , wherein the flame retardant is a halogenated bromine-containing compound.

14. The method according to claim 12 , wherein the flame retardant is a phosphorous compound and is selected from the group consisting of phosphates, phosphites, phosphonates, phosphinates, phosphine oxides, phosphines, phosphonium salts, and combinations thereof.

15. The method according to claim 1 , wherein introducing the at least one blowing agent into the polymer matrix and incorporated concentrate composition forms a foamable gel.

16. The method according to claim 1 , wherein the at least one carrier and the polymer matrix consist essentially of the same material.

17. The method according to claim 1 , wherein the at least one carrier and the polymer matrix do not consist essentially of the same material.

18. The method according to claim 1 , wherein the polymer matrix is selected from the group consisting of polystyrene, polyethylene, ethylene vinyl acetate (EVA), maleic anhydride grafted polymers, polyethylene terephthalate, poly(methyl methacrylate) (PMMA), polyamide, polycarbonate, styrene butadiene copolymers, acrylonitrile butadiene styrene, styrene acrylonitrile, styrene block copolymers, ethylene methyl acrylate copolymers, polyacrylonitriles, polyvinyl chloride, polyvinyl alcohol, melamine formaldehyde, urea formaldehyde, polymethyleneurea, natural rubber, synthetic rubber, elastomers, and biodegradable polymers.

19. A method of forming a polymeric foam with a uniform cell size distribution, the method comprising:

forming a concentrate composition comprising at least one carrier and dispersed therein from about 5% to about 70% by weight of at least one surface unmodified sepiolite clay;

incorporating the concentrate composition into a polymer matrix, wherein the polymer matrix is selected from the group consisting of polystyrene, polyethylene, ethylene vinyl acetate (EVA), maleic anhydride grafted polymers, polyethylene terephthalate, poly(methyl methacrylate) (PMMA), polyamide, polycarbonate, styrene butadiene copolymers, acrylonitrile butadiene styrene, styrene acrylonitrile, styrene block copolymers, ethylene methyl acrylate copolymers, polyacrylonitriles, polyvinyl chloride, polyvinyl alcohol, melamine formaldehyde, urea formaldehyde, polymethyleneurea, natural rubber, synthetic rubber, elastomers, biodegradable polymers, amino resins, alkyd resins, phenolic resins, epoxy resins, isocyanate resins, isocyanurate resins, polysiloxane resins, and mixtures thereof;

introducing at least one blowing agent into the polymer matrix and incorporated concentrate composition; and

processing the polymer matrix with the concentrate composition and at least one blowing agent, to thereby produce the polymeric foam having a uniform cell size distribution,

wherein the concentrate composition provides from about 0.10% to about 2.0% of the at least one surface unmodified sepiolite clay by weight of the polymer matrix with the concentrate composition, and

wherein the at least one carrier comprises a thermoset polymer selected from the group consisting of unsaturated polyesters, polyurethanes, amino resins, alkyd resins, phenolic resins, epoxy resins, isocyanate resins, isocyanurate resins, polysiloxane resins, and mixtures thereof.